SERVICE BULLETIN
B-016B
November 7, 2000
REVISED PRODUCT PROGRAM BP5 - ISOLATOR KIT
GENERAL
The complete revised isolator kit (Part No. Z0010.CB) consists of:
The purpose of this service bulletin is to inform you of a
revised isolator kit (Part No. Z0010.CB) and provide installation instructions. The original isolator kit has been revised to
include newly designed, improved rear isolators. In addition,
a revised tool was developed to assist in installing the new
rear isolators.
NOTE
The existing isolator replacement aid (Part No. 91430-96Y)
may be used until the new isolator tool (Part No. B44623)
becomes available.
●
(2) New Rear Isolators
●
(2) Bolts (low profile TORX)
●
Sprocket Cover
●
Lockwasher (for rear tie bar)
●
Cable Tie, Thin (for fuel tank vent)
●
Clamp (for fuel hose)
●
Locknut, metric (for X1 rear brake pedal)
●
(5) Locknuts (for X1 side plate and passenger footrest
mounting bracket)
VEHICLES INVOLVED
The revised isolator kit (Part No. Z0010.CB) has been developed for replacement of damaged isolators on all 1996-2000
model year Buell motorcycles (except S2 and S2T models).
Kits will be available beginning on or before December 1,
2000. Kits must be ordered as required and purchase price
will be reimbursed by warranty. See CREDIT PROCEDURES.
DEALER ACTION
The isolator tool will be shipped to your dealership when
available.
If a motorcycle is to be serviced for damaged isolators, and it
still has the old steel swingarm that was recalled, the steel
swingarm recall service (campaign #0816) should be performed in conjunction with this procedure. Discard isolators
provided in the swingarm recall kit and use the new isolators
provided in this kit (with new fasteners and new sprocket
cover provided) instead.
NOTE:
To guard against corrosion of its metal plates, each isolator is
painted after molding. It is normal for the paint that ends up
on the rubber portion of the isolator to crack. This may give
the false impression that the isolator is damaged. In addition,
it is normal for the rubber in the rear, upper corner of the isolator’s internal diameter to develop a small cut. When the
motorcycle is loaded, the isolator bolt head will cause this
small cut, which does not affect isolator performance. Inspect
each isolator carefully and order an isolator kit (Part No.
Z0010.CB) only for vehicles with damaged isolators.
If the motorcycle has either the new steel swingarm or the
aluminum swingarm and is suspected of having damaged
isolators, inspect isolators prior to disassembly to verify that
the isolators are actually damaged. If either isolator is indeed
damaged, this isolator kit should be used for replacement
under warranty. Vehicles beyond the warranty period will not
require a prior authorization. See CREDIT PROCEDURES.
This revised isolator kit (Part No. Z0010.CB) includes new
isolators, TORX bolts and sprocket cover. Do not use the old
isolators, Part Nos. 47680-94Y or 47564-86, for replacement
purposes.
ROUTING
SERVICE
MANAGER
SALES
MANAGER
PARTS
MANAGER
LEAD
TECHNICIAN
The life expectancy of this product program is one year from
the date of issue of this bulletin.
KIT INSTALLATION
Rear Isolator Removal
(S1, S1W, M2, S3/S3T Models)
●
NOTE
Perform the following procedures according to the guidelines given in the service manual for the model being serviced.
●
Mark all hardware as it is removed so that it may be
returned to its original location.
1.
Position motorcycle on a suitable lift and secure front
wheel to lift.
1WARNING
To avoid accidental start-up of vehicle and possible personal injury, disconnect the battery cables before proceeding. Always disconnect the negative battery cable
first. If the positive cable should contact ground with the
negative cable installed, the resulting sparks may cause
a battery explosion, which could result in death or serious injury.
2.
Disconnect both battery cables from battery, negative
cable first.
TECHNICIAN
NO. 1
TECHNICIAN
NO. 2
TECHNICIAN
NO. 3
INITIAL HERE
©2000 Buell Distribution Corporation
TECHNICIAN
NO. 4
RETURN
THIS TO:
3.
S1/S1W, M2, S3/S3T: Remove seat and fuel tank.
S1/S1W models only: Remove tail section. See appropriate service manual, Sections 2 and 4 for procedures.
4.
Remove the left side rider footpeg mounting bolt and
footpeg. Allow footpeg and shift linkage to hang being
careful not to scratch primary cover.
5.
See Figure 1. On the right side of the motorcycle,
remove the front sprocket cover assembly (and remove
fairing lower hardware on S3T models). See appropriate
service manual, Section 2 for procedure.
6.
See Figure 1. Remove two screws that attach sprocket
cover to the backside of the swingarm/drive support.
Retain screws. Discard sprocket cover.
NOTE
See Figure 2. For M2 and S3/S3T models route strap under
frame rails with tail section installed. Make sure strap is in “V”
formed by frame rails to prevent rearward movement and that
it does not pinch wiring harness, vent lines or cables.
7.
See Figures 2 and 7. Strap tail section of frame to overhead beam or hoist and put slight tension on strap to
secure frame assembly.
8.
See Figure 8 (typical). Remove frame side tie bar mounting hardware from front lower and center tie bars. If
present, leave fourth tie bar (front upper) attached to
both frame and engine.
9.
See Figure 3. Remove rear tie bar bolt, lockwasher and
washers from mount block. Discard lockwasher.
b0204x2a
Screws (2)
Blue Loctite
Spacer
Sprocket
Cover
Screw
48-72 in-lbs
(5-9 Nm)
Blue Loctite
Screws (2)
20-25 ft-lbs
(27-34 Nm)
Red Loctite
Locknut
30-35 ft-lbs
(41-47 Nm)
Swingarm/Drive
Support
Figure 1. Sprocket Cover
10. See Figure 3. Loosen left side isolator bolt from swing
arm bearing adjusting bolt. Do not remove.
11. See Figure 3. Remove right side isolator bolt and washer
from swingarm bearing adjustment bolt. Discard isolator
bolt, but retain washer.
12. See Figure 4. Working on the right side first, insert the
rear isolator replacement tool between mount block and
frame. NOTE: Ledge on tool should engage top of mount
block.
CAUTION
Do not alter tool or shim in an attempt to spread frame
further than tool will allow. Failure to comply may result
in frame distortion or damage.
13. Turn nut on rear isolator replacement tool clockwise to
expand frame from swingarm mount block until isolator
can be removed. Nut will stop when limit of travel is
reached.
14. Disengage right side rear isolator from roll pin in frame
by pulling inboard. Remove isolator by pulling out from
5:00 or 6:00 position. Discard rear isolator.
15. Remove rear isolator replacement tool by turning nut
counterclockwise.
16. Remove left side isolator bolt and washer from bearing
adjusting bolt. Discard isolator bolt, but retain washer.
17. Remove nut and back out bolt (until flush with the mount
block) from upper rear of muffler Z bracket attachment to
swingarm mount block.
18. Pull frame to left and remove left side isolator from 6:00
or 7:00 position. Discard isolator.
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B-016B
Rear Isolator Installation
(S1, S1W, M2, S3/S3T Models)
8264
NOTE
If roll pin protrudes beyond specification, check to make sure
it is fully seated. A channel lock pliers may be used to
squeeze/push roll pin in. Protect frame with a shop rag when
using pliers.
1.
See Figure 5. Measure isolator roll pin protrusion on both
left and right isolator mounts with calipers or metal rule.
Roll pin should not protrude more than 0.120 in. (3 mm).
If roll pin protrudes more than 0.120 in. (3 mm) file or
grind until within specification; 0.080-0.120 in. (2.0323.048 mm). Use care when filing to avoid creating sharp
edges.
2.
See Figure 3. On left side of motorcycle, align locator
hole with roll pin and install new left rear isolator provided in kit. The left isolator backing plate has an “L”
stamped on it.
3.
Move to right side of motorcycle. Lower the frame
approximately one inch with the hoist to allow clearance
between isolator replacement tool and the new larger
isolator.
4.
Strap
Frame
Rails
See Figure 4. On right side of motorcycle, insert rear isolator replacement tool between mount block and frame.
CAUTION
Top View
Do not alter tool or shim in an attempt to spread frame
further than tool will allow. Failure to comply may result
in frame distortion or damage.
5.
Turn nut on tool clockwise to expand frame from mount
block. Nut will stop when limit of travel is reached.
6.
See FIgure 3. On right side of motorcycle, align locator
hole with roll pin and install new right rear isolator provided in kit. The right isolator backing plate has an “R”
stamped on it.
7.
Turn nut on tool counterclockwise to allow frame to
return to position. Remove tool from between frame and
mount block.
8.
Raise frame with hoist to align isolator bolt holes with
threaded holes in bearing adjusting bolts.
9.
See Figure 6. Mark a horizontal line across the front of
each isolator with a light colored grease pencil or by
other non-permanent means.
8263
Bottom View
Strap
“V” formed
by frame
rails
10. Apply anti-seize to underside of new isolator bolt heads.
CAUTION
Use caution when installing isolator bolts. Make sure isolator bolt hole is aligned with threaded hole in bearing
adjusting bolt to avoid cross-threading bolt.
11. See Figure 3. Install new isolator TORX bolts and washers through both rubber isolators into bearing adjustment
bolts on each side.
Figure 2. Floor Hoist - M2, S3/S3T Models
12. Tighten right and left isolator bolts to 63-70 ft-lbs (85-95
Nm).
13. Push rear upper Z bracket bolt until it protrudes from
mount block and install nut. Tighten rear upper Z-bracket
bolt to 17-19 ft-lbs (23-26 Nm).
CAUTION
14. Erase grease pencil marked lines from both isolators.
See Figure 6. Observe marked line on both rubber isolators after isolator bolts are tightened. If line twists, apply
more LOCTITE ANTI-SEIZE to underside of isolator bolt
heads. Failure to comply will result in damage to rubber
isolators.
B-016B
15. Install front lower and center tie bars to frame with original locknuts. Tighten bolts to 30-33 ft-lbs (41-45 Nm).
Install rear tie bar to mount block with new lockwasher.
Tighten bolt to 30-33 ft-lbs. (41-45 Nm).
3 of 7
16. Remove hoist from tail section.
17. Install left side rider footpeg. Tighten bolt to 25-30 ft-lbs
(34-41 Nm).
b0202c3x
*Lockwasher
18. See Figure 1. Apply LOCTITE THREADLOCKER 243
(Blue) to threads of two sprocket cover to swingarm/drive
support screws and install new sprocket cover to swingarm/drive support.
Rear Tie Bar
19. See Figure 1. Install new sprocket cover assembly with
original hardware.
a.
Apply LOCTITE THREADLOCKER 243 (blue) to
screw. Install sprocket cover assembly with screw,
washer and spacer. Tighten to 48-72 in-lbs (5.4-8.6
Nm).
b.
Apply LOCTITE THREADLOCKER 272 (red) to
swingarm/drive support mounting screws and
install. Tighten screws to 20-25 ft-lbs (27.1-33.9
Nm).
c.
Install locknut and washer. Tighten to 30-35 ft-lbs
(40.7-47.4 Nm).
Bearing
Adjusting
Bolt
*Isolator
*Isolator
TORX Bolt
* Included in Kit
Figure 3. Mount Block
1WARNING
After installing seat, pull upward on front of seat to be
sure it is locked in position. If seat is loose, it could shift
during vehicle operation resulting in loss of control of
vehicle and death or serious injury.
Replacement
Tool
20. Install fuel tank and seat (and tail section on S1/S1W
models). See appropriate service manual, Sections 2
and 4 for procedures. NOTE: Use new thin cable tie and
hose clamp provided in kit on fuel tank.
Ledge
Rear
Isolator
1WARNING
Always connect the positive battery cable first. If the
positive cable should contact ground with the negative
cable installed, the resulting sparks may cause a battery
explosion, which could result in death or serious injury.
Frame
Mount Block
21. Connect battery cables, positive cable first, to battery terminals.
22. Test ride motorcycle at low speed and check for proper
operation.
b0869x2x
Figure 4. Rear Isolator Replacement Tool In Use
Pin
0.080-0.120 in.
(2.032-3.048 mm)
Figure 5. Measuring Roll Pin Protrusion
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B-016B
Rear Isolator Removal (X1 Models)
b0674b2x
●
Rear Isolator
NOTE
Perform the following procedures according to the guidelines given in the service manual for the model being serviced.
●
Mark all hardware as it is removed so that it may be
returned to its original location.
1.
Position motorcycle on a suitable lift and secure front
wheel to lift.
Marked
Line
1WARNING
To avoid accidental start-up of vehicle and possible personal injury, disconnect the negative battery cable
before proceeding. If the positive cable should contact
ground with the negative cable installed, the resulting
sparks may cause a battery explosion, which could
result in death or serious injury.
2.
Disconnect negative battery cable from battery terminal.
3.
Remove seat, fuel tank cover and fuel tank. See appropriate service manual sections 2 and 4 for complete procedure.
4.
See Figure 8. Strap frame, just forward of tail section, to
overhead beam or hoist and put slight tension on strap to
secure frame assembly.
5.
See Figure 8. Remove frame side tie bar mounting hardware from front lower and center tie bars. Leave fourth
tie bar (front upper) attached to both frame and engine.
Discard locknuts.
6.
See Figure 3 (Typical). Remove rear tie bar bolt, lockwasher and washers from mount block. Discard lockwasher.
7.
See Figure 3. Loosen left and right isolator bolts. Do not
remove.
8.
See Figure 8. Remove two screws, locknuts and right
side passenger footrest mounting bracket from frame.
Discard locknuts.
9.
Remove screw and locknut from rear brake pedal that
attaches actuator rod to rear brake master cylinder. Discard locknut.
10. Remove two screws that attach rear brake master cylinder to right side plate.
Straight Line
(Correct)
Twisted Line
(Incorrect)
OBSERVE MARKED LINE WHILE TIGHTENING
Figure 6. Checking Isolator Alignment
b0420x3x
1 TON
3/4 TO
N
Figure 7. Floor Hoist -S1/S1W Models
18. See Figure 1. Remove two screws that attach sprocket
cover to the backside of the swingarm/drive support.
Retain screws. Discard sprocket cover.
11. See Figure 8. Remove three screws, locknuts and right
side plate from frame. Discard locknuts.
12. Remove nut and back out bolt (until flush with the mount
block) from upper rear of muffler Z bracket attachment to
swingarm mount block.
13. Remove right side isolator bolt, washer and isolator. Discard bolt. Retain washer.
14. Remove left side isolator bolt and washer. Discard bolt.
Retain washer
15. Pull frame to left and remove isolator from 6 or 7 o’clock
position.
16. Discard original isolators.
17. See Figure 1. On the right side of the motorcycle,
remove the front sprocket cover assembly. See appropriate service manual, Section 2 for procedure.
B-016B
5 of 7
Rear Isolator Installation (X1 Models)
1.
2.
See Figure 1. Apply LOCTITE THREADLOCKER 243
(Blue) to threads of two sprocket cover to swingarm/drive
support screws and install new sprocket cover to swingarm/drive support.
See Figure 1. Install new sprocket cover assembly with
original hardware.
a.
Apply LOCTITE THREADLOCKER 243 (blue) to
screw. Install sprocket cover assembly with screw,
washer and spacer. Tighten to 48-72 in-lbs (5.4-8.6
Nm).
b.
Apply LOCTITE THREADLOCKER 272 (red) to
swingarm/drive support mounting screws and
install. Tighten screws to 20-25 ft-lbs (27.1-33.9
Nm).
c.
Install locknut and washer. Tighten to 30-35 ft-lbs
(40.7-47.4 Nm).
NOTE
If roll pin protrudes beyond specification, check to make sure
it is fully seated. A channel lock pliers may be used to
squeeze/push roll pin in. Protect sideplate with a shop rag
when using pliers.
b0857x2x
Mounting
Bracket (2)
Center
Tie Bar
Strap
Location
Side
Plate
Screw
13-16 ft-lbs
(17.6-21.7 Nm)
Red LOCTITE
Front Lower
Tie Bar
Front Upper Tie Bar
(Do Not Remove)
Figure 8. Frame Assembly (X1 Shown)
3.
See Figure 5. Measure isolator roll pin protrusion on both
left and right isolator mounts with calipers or metal rule.
Roll pin should not protrude more than 0.120 in. (3 mm).
If roll pin protrudes more than 0.120 in. (3 mm) file or
grind until within specification; 0.080-0.120 in. (2.0323.048 mm). Use care when filing to avoid creating sharp
edges.
4.
See Figure 3. On left side of motorcycle, align locator
hole with roll pin and install new rear isolator provided in
kit.
CAUTION
Use caution when installing isolator bolts. Make sure isolator bolt hole is aligned with threaded hole in bearing
adjusting bolt to avoid cross-threading bolt.
5.
See Figure 3. Loosely install new isolator TORX bolt and
washer through rubber isolator into bearing adjusting
bolt. Do not tighten.
6.
On right side plate, align locator hole with roll pin and
install new rear isolator provided in kit.
7.
See FIgure 6. Mark a horizontal line across the front of
each isolator with a light colored grease pencil or by
other non-permanent means.
8.
Apply anti-seize to underside of isolator bolt head.
CAUTION
Use caution when installing isolator bolts. Make sure isolator bolt hole is aligned with threaded hole in bearing
adjusting bolt to avoid cross-threading bolt.
9.
Install new isolator TORX bolt and washer through rubber isolator into bearing adjustment bolt. Do not tighten.
10. See Figure 8. Install right side plate with three screws
and new locknuts. Tighten side plate mount screws to
16-19 ft-lbs (21.7 -25.8Nm).
6 of 7
B-016B
CAUTION
See Figure 6. Observe marked line on rubber isolator
after isolator bolt is tightened. If marked line twists,
apply more LOCTITE ANTI-SEIZE to underside of isolator
bolt heads. Failure to comply will result in damage to
rubber isolators.
CREDIT PROCEDURES
After servicing each vehicle, file a warranty claim referencing
Service Bulletin B-016B in the “Description of Repair” or “Comments” section of the claim. Fill in the rest of the claim as follows:
Claim Type*
BP5
11. Tighten right and left isolator TORX bolts to 63-70 ft-lbs
(85-95 Nm).
Event 1, Qty & Problem
Part No.
0-47564-86
12. Push rear upper Z bracket bolt until it protrudes from
mount block and install nut. Tighten rear upper Z-bracket
bolt to 8-10 ft-lbs (11-14 Nm).
Event 1, Additional
(Replacement) Qty & Part No.
1- Z0010.CB
13. Erase grease pencil marked lines from both isolators.
Primary Labor Code
14. Apply LOCTITE 243 (Blue) to threads of two master cylinder mounting screws.
Time:
Customer Concern Code
9203
15. Install rear brake master cylinder to right side plate with
two screws. Tighten screws to 8-10 ft-lbs (10.8-13.6 Nm).
Condition Code
2101
16. Install actuator rod to rear brake pedal with new locknut
(metric). Tighten locknut to 7-9 ft-lbs (9.5-12.2 Nm).
17. See Figure 8. Install right side passenger footrest mounting bracket with two screws and new locknuts. Tighten
screws to 13-16 ft-lbs (17.6-21.7 Nm).
Part Description
●
●
Rear Isolator Kit
2375
1.0 (All Models)
NOTE
If additional parts such as cable straps are required, list
them under Event 1, Additional Parts.
Use of incorrect claim type will cause claim to be
rejected and credit delayed.
18. See Figures 3 and 8. Install front lower and center tie
bars to frame with original locknuts. Tighten bolts to 3033 ft-lbs (41-45 Nm). Install rear tie bar to mount block
with new lockwasher. Tighten bolt to 30-33 ft-lbs. (41-45
Nm).
19. Remove hoist from tail section.
1WARNING
After installing seat, pull upward on front of seat to be
sure it is locked in position. If seat is loose, it could shift
during vehicle operation resulting in loss of control of
vehicle and death or serious injury.
20. Install fuel tank, fuel tank cover and seat. See appropriate service manual, sections 2 and 4 for complete procedures.
21. Connect negative battery cable to negative battery terminal.
1WARNING
Check for proper brake lamp operation before riding
motorcycle. Visibility is a major concern for motorcyclists. Failure to have proper brake lamp operation could
result in death or serious injury.
22. Turn ignition key ON, depress rear brake pedal and
check for proper brake light operation.
23. Test ride motorcycle at low speed and check for proper
operation.
B-016B
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